GUTMER system enables full control of conveyor belt production process on vulcanization presses.gutmer

The system implemented in SEMPERTRANS Bełchatów  Factory serves to operate the production lines of conveyor textile-reinforced belts and steel cord belts. The system’s start-up on the first line was held in year 2003. During the next years the system was implemented on consecutive lines. The system was modernized and developed several times with new functions since then.

GUTMER is an union of two systems:

  • Automation system which is to control conveyor belt production process,
  • Supervisory system – MES class (Manufacturing Execution System) which is to manage and to monitor production process.

Automation system is impelemented using programmable PLC controllers, located in the production area, nearby to monitored processes. Controllers supervise production line elements – belt preparation system, vulcanization press, drawler and coiler.

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Automation system is responsible for management of the belt vulcanization technological process in accordance with the recipe, sent form the supervisory system. Programmable controllers ensure the implementation of the defined work sequences of devices and maintenance of monitored process set points (pressure, temperature, time).

The process is visualized on the panels located on the operator stands. The status of controlled devices and the level of the analogue amounts, displayed on the panels, supports the operators to supervise the process.

The production line server carry on the communication with the superior system. Information, given by the superior layer, which determine the process, are inserted to the PLC controllers by the technological line server. Site data read by the technological line server from the PLC controllers is the source of process data for the superior layer. The server of the technological line ensures also data buffering when communication loss occurs.

The supervisory system manages the production process – cerates the queue of orders, transfers the parameters to automation system and controls the course of the proces (technological parameters registration, outages and productivity data).

Supervisory system consists of the department database server (redundant), and computer workstations (department or dispatcher’s).

Department database server is responsible for collecting and storing the data concerning process course (trends, alerts, events) as well as order realization parameters (set up and realized process paramaters’ values for each process cycle).

Processed data is transferred to department server through the production line server, which provides also the data buffering.

Superior system’s main functions:

  • completion of production orders (provided by SAP),
  • recipe databank service (set point values for vulcanization process),
  • queue of orders management (for production and repair lines),
  • providing vulcanization process set point values for automation system (temperature, pressure, times, etc.),
  • automatic registering of technological parameters value (continuously as trends and as a summary for each batch),
  • emergency events automatic registering (alarms, alerts),
  • providing of the measurements results made by line’s operators (manually),
  • materials used for production data providing,
  • production lines productivity and outages causes data registering,
  • product faults and it’s repair data registration also the repair order creating for the faults which cannot be fixed during production,
  • automatic coefficients calculating (for quality department),
  • reports creating.